Winch Fairlead Interface Curved Surfaces Cable Damage

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Solution Overview

Problem

Existing winch systems face issues with damage to the fairlead due to forceful contact between the metal cable terminal and the fairlead, leading to reduced functionality.

Innovation Solution

A rigging interface and rigging device with curved surfaces are designed to nest with the fairlead, acting as a cable terminal that couples with other rigging devices, while maintaining a geometry that prevents damage to the fairlead.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a metal cable terminal is used to couple with the fairlead, then the cable terminal can be securely attached to the winch cable, but the fairlead surface may be damaged due to forceful contact

Engineering Contradiction:

Improvecable terminal attachment strengthVSAvoidfairlead surface damage

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a fairlead interface component as an intermediary between the metal cable terminal and the fairlead. This interface element absorbs the impact forces and prevents direct contact between the hard metal terminal and the fairlead surface, thereby protecting the fairlead from damage while maintaining secure cable attachment

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The fairlead interface is designed with cushioning properties to absorb impact forces before they reach the fairlead surface. By providing this protective layer in advance, the system prevents damage during rapid cable winding operations when the terminal contacts the fairlead with force

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Productivity

If the cable terminal directly contacts the fairlead during rapid winding, then the cable can be quickly retracted, but the terminal may become jammed in the fairlead

Engineering Contradiction:

Improvecable retraction speedVSAvoidcable terminal operation reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The fairlead interface acts as a mediator that guides the cable terminal through the retraction process, preventing the terminal from becoming jammed in the fairlead while maintaining rapid retraction capability

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If a rigid cable terminal is used for secure attachment, then the attachment strength is improved, but the impact force on the fairlead increases

Engineering Contradiction:

Improveattachment strengthVSAvoidimpact force on fairlead

Core Design Contradiction:

StrengthVSForce

Solution Approach 1:

The fairlead interface component serves as an intermediary that decouples the rigid cable terminal from the fairlead, allowing the terminal to maintain its attachment strength while the interface absorbs and distributes the impact forces

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the physical parameters of the contact interface by introducing a fairlead interface with different material properties and geometric characteristics, transforming the direct hard contact into a more compliant interaction that reduces impact forces

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12215006B2Systems for winch rope interfaces and recovery rigging mountable to a winch fairlead and/or vehicle bumper

Publication Date: 2025.02.04 WARN INDUSTRIES INC

AI summary

Methods, apparatus, and systems are provided for rigging interfaces couple to winch cable terminals that protect outer surfaces of fairleads and rigging devices as connections between objects. In one example, a rigging interface may include curved surfaces adapted to nest against a fairlead. In another example, a rigging device may have one or more removable elements allowing for coupling of the device to other objects.